Sikorsky has revealed the Phase IV main gearbox for its S-92 helicopter, a significant innovation that is said to raise the bar for reliability, performance and safety in the commercial helicopter industry.

The new Phase IV gearbox features an auxiliary lubrication system that automatically engages if primary oil pressure is lost, eliminating the need for immediate landing and allowing operators to safely reach their destination. This solution has been validated through more than 800 hours of rigorous testing, with Federal Aviation Administration (FAA) certification expected in 2025. Four completed gearboxes have been produced at Sikorsky's Stratford, Connecticut, headquarters, and the company reports that customers are eager to adopt the technology.

“The Phase IV main gearbox builds upon its predecessor’s reputation as one of the best and most reliable gearboxes in the industry, and is yet another example of Sikorsky’s continued investment in the S-92 platform,” says Leon Silva, vice president of global commercial and military systems at Sikorsky. “We have spent more than a decade designing, testing and optimising the Phase IV main gearbox for exceptional performance, and we are thrilled to see it become a new industry standard.”

Sikorsky invested more than $100 million in the development of the Phase IV gearbox, enabling customers to meet the evolving demands of future missions and reaffirming the company’s commitment to enhancing the S-92 platform. The S-92 is the helicopter of choice for the offshore energy industry and remains a trusted choice for search and rescue, head of state transportation and other critical operations worldwide.

The unveiling of the Phase IV main gearbox is a milestone in Sikorsky’s ongoing efforts to improve the capability and safety of the S-92 fleet. With an average lifetime availability of over 90 per cent, many S-92 helicopters in the offshore energy sector log more than 1,500 flight hours per year. As the offshore energy industry continues to grow, the new gearbox is well positioned to support the increasing demands of deepwater operations, ensuring safe and reliable transport of personnel, equipment and supplies to remote locations.

In recent months, Sikorsky has introduced several enhancements for the S-92, including extended scheduled inspection intervals and a one-time life extension for certain main gearbox housings. These improvements will eliminate more than a full year of downtime caused by inspections and enable operators to keep their aircraft in service and generating revenue for longer periods. The earned life credit is up to 1,200 hours or 3,600 ground-air-ground cycles, providing an additional 12 to 18 months of service for an average offshore oil operator and more than 24 months for other users.